Adjustable tilt solar panel support system

ABSTRACT

An adjustable tilt solar panel support system including a support post, a pivot bracket attached to the support post in a generally upright orientation and having a pivot pin hole for accommodating a pivot pin, and further having at least one adjustment opening; a rotational support cradle having a pivot pin hole in alignment with the pivot pin hole of the pivot bracket, such that the support cradle is pivotally attached to the pivot bracket, the support cradle further including at least one adjustment opening which aligns with the adjustment opening of the pivot bracket. An adjustment pin is selectively inserted into and through the adjustment openings of the support cradle and pivot bracket to secure the support cradle at a selected angle, and wherein the removal of the adjustment pin permits the rotational support cradle to pivot on the pivot bracket about the pivot pin. Beam holders for securing support beams are disposed atop the rotational support cradle.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application is a continuation of U.S. Utility patentapplication Ser. No. 12/160,129, filed Jul. 7, 2008, which claims thebenefit of the filing date of U.S. Provisional Patent Application Ser.No. 60/910,202, filed Apr. 4, 2007.

SEQUENCE LISTING

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OR PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to solar panel photovoltaicsystems, and more particularly to solar panel array installations, andstill more particularly to an adjustable tilt able support apparatus fora solar panel module array.

2. Discussion of Related Art Including Information Disclosed Under 37CFR 1.97, 1.98

Numerous kinds of support apparatus for solar panels are well known.Indeed, the present inventors have contributed significantly to thefield, including disclosure of a solar panel array sun tracking systemthat describes a support cradle employed in the present invention. Thatinventive system was disclosed International Patent Application SerialNumber PCT/US06/38185, and it is incorporated by reference in itsentirety herein.

Known published documents in the prior art include U.S. Pat. No.6,563,040, to Hayden et al., which describes a tracking system tilted ina fixed southerly orientation. The tilt is fixed and is rotated east towest to track the diurnal arc of the sun.

U.S. Patent Application Publication No. 2004/0238025 A1, by Shingletonet al., describes a tilt able solar panel array system in which the tiltis fixed. It, too, is rotated to track the diurnal arc of the sun. Theassembly includes southside supports, north side supports and supportstructures, each having pivotal support points defining a tilt axis andat least one solar collector mounted on the structures. The assemblyfurther includes apparatus that makes the collector support structuresand the solar collectors tilt in unison.

U.S. Pat. No. 6,089,224, to Poulek, shows an apparatus for automatic,motorized orientation of solar radiation collectors. It includes one ormore solar cells fixed to a rotary axle of the apparatus and connecteddirectly to an electromotor joined with a rotary axle. The solar cell isarranged on the rotary axle in such a way that a plane of the solar cellis inclined by an angle between 0.1 degrees and 45 degrees from a planeperpendicular to the collectors of solar energy and parallel with therotary axle apparatus in a direction opposite to the direction of sunmovement. The solar cell is connected to the electromotor fororientation of the rotary axle and an associated orientation of theradiation collectors as long as the power of the solar cell is higherthan the power necessary for orientation of the rotary axle.

Solar modules in collector arrays that do not follow the motion orposition of the Sun are known as fixed tilt systems. Solar modules infixed tilt systems are generally mounted on stationary structures tohave an angle of inclination set to optimize the capture of sunlightthroughout the day and throughout the year. Depending on the latitude ofthe array location, the angle of inclination may vary substantially.Further, as the Sun's position changes during the year (or moreaccurately, as the angle between the Earth's axis and the Earth-Sun linechanges throughout the year), the capture efficiency of a solar modulein a fixed title system is significantly affected, at times adversely.

Accordingly, fixed tilt solar power systems are closely analyzed todetermine the module angular position with the highest solar yield sothat the support system can be constructed accordingly. Once the angleof inclination is determined, the support structure can be specified andconstructed. Such assemblies consist of combinations of structuralmaterials, typically including a concrete base structure, structuralsteel members such as channels and angles to support the modules and toset the angle of inclination, and struts or channels to mount themodules. The structures are welded and/or bolted into frameworks toprovide rigid support for the modules.

Although this method of support provides the necessary support structurefor operation of a solar panel or panel array, there are a number oflimitations. Notably, a fixed tilt stationary mounting system is (bydefinition) fixed. It therefore cannot be adjusted for seasonal changesin the Sun's relative position, and this dramatically limits solarcollection efficiency.

Next, in a fixed tilt system the angle of inclination must be determinedbased on the latitudinal position of the solar array. Therefore thedesign of the structure cannot be finalized until the construction siteis precisely known.

Next, with few exceptions, the angular position of the structurerequires that the modules be mounted in an unstable orientation, andthis may cause additional assembly effort as well as increase thepotential for damage to the modules.

The foregoing prior art devices and patents reflect the current state ofthe art of which the present inventors are aware. Reference to, anddiscussion of, these patents is intended to aid in dischargingApplicants' duties of candor in disclosing information duringexamination that may be materially relevant to the allowability ofclaims to the present invention. However, it is respectfully submittedthat none of the above-indicated patents or prior art apparatusdiscloses, teaches, suggests, shows, or otherwise renders obvious,either singly or when considered in combination, the invention describedherein.

BRIEF SUMMARY OF THE INVENTION

The adjustable tilt system of the present invention provides aninexpensive and elegant solution to the foregoing problems. Theinventive system includes the following objects, advantageous,characteristics, and features:

It is a first and principal object of the present invention to providean adjustable tilt solar panel support that can be set for the bestangular position to optimize solar collection.

It is another object of the present invention to provide an adjustabletilt solar panel support that permits a solar module array to beadjusted from time to time to optimize solar collection throughout theseasonal changes.

It is yet another object of the present invention that theabove-described adjustments be easily accomplished using a simpleangular adjustment tool forming a part of the inventive system.

A still further object of the present invention is to provide anadjustable tilt solar panel support that eliminates the need to buildand fix a solar panel array at a specified angle.

Another object of the present invention is to provide an adjustable tiltsolar panel support that can be mounted in a system arrangement on agroup of micropile posts using existing support technology withadjustable height inserts for ease of assembly.

Yet another object of the present invention is to provide an adjustabletilt solar panel support that may be set at a horizontal position toensure safe and easy assembly of solar panel modules on the supportsystem.

Summarily, a principal object and advantage of the present invention isto provide a stationary solar panel mounting system with means to effectand easy, manual adjustment of a solar panel array to the Sun's southernexposure without the need for motorized apparatus.

The foregoing summary broadly sets out the more important features ofthe present invention so that the detailed description that follows maybe better understood, and so that the present contributions to the artmay be better appreciated. There are additional features of theinvention that will be described in the detailed description of thepreferred embodiments of the invention which will form the subjectmatter of the claims appended hereto.

Accordingly, before explaining the preferred embodiment of thedisclosure in detail, it is to be understood that the disclosure is notlimited in its application to the details of the construction and thearrangements set forth in the following description or illustrated inthe drawings. The inventive apparatus described herein is capable ofother embodiments and of being practiced and carried out in variousways.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based may readily be used as a basis fordesigning other structures, methods, and systems for carrying out theseveral purposes of the present invention. It is important, therefore,that the claims are regarded as including such equivalent constructionsas far as they do not depart from the spirit and scope of the presentinvention. Rather, the fundamental aspects of the invention, along withthe various features and structures that characterize the invention, arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the presentinvention, its advantages and the specific objects attained by its uses,reference should be made to the accompanying drawings and descriptivematter in which there is illustrated the preferred embodiment and bestmode of practicing the invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will be better understood and objects other than those setforth above will become apparent when consideration is given to thefollowing detailed description thereof. Such description makes referenceto the annexed drawings wherein:

FIG. 1 is a schematic side view in elevation showing the structuralelements of the support cradle employed in the present invention,showing the rotational support beams removed for clarity;

FIG. 2 is a schematic front view in elevation thereof;

FIG. 3 is a schematic side view in elevation showing the support cradlehaving the angular adjustment tool of the present invention installedfor an adjustment procedure;

FIG. 4 is a schematic front view in elevation thereof;

FIG. 5 is a lower rear perspective view showing the adjustable tiltsolar panel support system with solar panels mounted on the supportcradle; and

FIG. 6 is a lower rear perspective view showing two adjustable tiltsupport systems supporting solar panels in a tilted orientation beforeor after adjustment.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 through 6, wherein like reference numerals refer tolike components in the various views, there is illustrated therein a newand improved adjustable tilt solar panel support apparatus, generallydenominated 100 herein.

The inventive apparatus includes a rotational support cradle 110, whichis the primary rotational and adjustment element of the system. Therotational support cradle, in its most essential aspect, comprisessubstantially planar parallel elongate side bars 106, 108, joined by aplurality of cross bars 112, 114, 116, 118. Each side bar preferablyincludes an expanded medial portion 107, 109, so as to accommodate theadjustment features described below. Using a pivot pin 120 therotational support cradle is mounted to a pivot bracket 130, which inturn is attached to a support post or cinch tube 140 adjustably insertedinto, and secured in, a piling 150. The cinch tube includes either anexpander or wedge at its lower end and either an angled lower end (foruse with the wedge) or a slotted lower end (for use with an expander).The expander or wedge is brought into engagement with the lower end ofthe cinch tube and tightened with a connecting bolt, and therebyoperates in the manner of a bicycle handlebar stem to provide verticaladjustability within the piling tube.

The rotational support cradle, preferably fabricated from structuralsteel, is used to mount and rotate rotational support beams 160 aboutthe pin axis to a desired angle of inclination. The side bars of therotational support cradle include a plurality of aligned angleadjustment holes 172, 174, 176, 178, in an arcuate array, such that asthe rotational support cradle is rotated relative to the pivot bracket,the angle adjustment holes can be aligned in various angular positionsfor insertion of an alignment pin 180. The series of angle adjustmentholes preferably includes four or five pairs of holes, including themain pivot pin holes, that allow setting the rotational support cradleposition at the desired angles of inclination. Those positionspreferably include stops at various angle settings, in this instance 10degrees 172, 20, degrees 174, 30 degrees 176, and 40 degrees 178. Aswill be immediately appreciated, however, any of a number of settingsfor the angle adjustment holes may be provided. Alternatively,continuous and arcuate angle adjustment slots may be cut in the sidebars, though setting and maintaining the angle of the rotational supportcradle would then entail using fasteners or other stop means, andpotentially the application of significant forces on the rotationalsupport cradle 110 and the bracket 130. Such forces could compromisesthe advantages gained by the infinite adjustability of a slot and makessuch an arrangement structurally disadvantageous. Further, because suchan arrangement may entail the use of fasteners rather than pins,adjustments would be significantly more involved and time consuming.

The rotational support beams 160 are preferably rectangular or square incross section and span the distance between adjacent rotational supportcradles in a solar panel support array (see FIG. 6). They are capturedand secured to the upper portion of the rotational support cradles withsplice clamps 190, which span transversely across the support cradleside bars where they are welded, bolted, or otherwise secured in upperand lower sets of cutouts 192, 194, in the upper edges of the rotationalsupport cradle side bars. The cutout sets conform in shape to the spliceclamps disposed in the cutouts, which in turn correspond to thecross-sectional shape of the rotational support beams, and the assemblythus functions as the principal support members for the solar panelarray.

The pivot bracket is a U-shaped bracket used to connect the rotationalsupport cradle by means of a pivot pin to the post or piling by means ofa slotted hole and cinch tube connecting bolt 200. It includes two ormore angular positioning holes in its vertical sides to accommodate thealignment pin.

To adjust the angle of the tilt able solar panel support system aspecial angular adjustment tool 210 is first installed on the rotationalsupport cradle. The adjustment tool includes an arm 220 having twoangled fingers 230 that fit over the medial shoulders 240 on one side ofthe rotational support cradle, and two angled base elements 250 that fitunder the side of the rotational support cradle to provide a firm gripfor rotating and adjusting the rotational support cradle about its pivotpin 120.

Next, an adjustment bracket 260 is installed on the cinch tube 140 orpiling post 150. This bracket provides a platform for hosting an eyehook 270 with a swivelable threaded female element 280 which receives amale end 290 of a threaded adjustment rod 300. An adjustment knob 310 isdisposed at the other end of the adjustment rod. The adjustment rod ispivotally connected to the lower end 315 of arm 220 so that it can berotated freely at the connection point.

To complete an angle adjustment, the adjustment rod is installed andinserted into the swivelable threaded female element 280, and theadjustment knob is then turned until the rod bears the weight of thesolar panel 320 and the alignment pin is free to be removed. Afterremoving the adjustment pin, adjustments to the angle of the rotationalsupport cradle can be made easily and quickly simply by turning theadjustment knob. The knob is turned until the next desired setting isreached and the angle adjustment hole is aligned with the hole in thepivot bracket. The adjustment pin is then reinserted and the rotationalsupport cradle is secured in at its new position.

Referring now to FIG. 6, when panels are mounted in an array on aplurality of aligned pilings (support posts) and rotational supportcradles, the rotational support cradles are structurally and operativelyconnected to one another using the rotational support beams and clampedin place with the end caps. Once the rotational support beams connectthe rotational support cradles, an entire row of mounted solar panelscan be rotated in unison about their respective pivot pins' shared axesof rotation. FIG. 6 shows a lateral mounting structure for a solar panelarray that allows a group of modules or side-by-side panels 320 to bemounted on rotational support beams (i.e., rails) 160 and deployed oneach side of a cinch tube 140 and piling 150, generally with pairs ofside-by-side panels mounted in series in an end-to-end fashion. Becauseof the lengths of the panels and their support structures, and becausethe panels are rotated and adjusted in coordination, substantial supportstructure is required, and this typically calls for two or morerotational support beams 160, shown herein as substantially squaretubes. Other support structure can be provided, including rectangulartubes, round tubes, pipe, I-beams, and channels. The mounting rails areaffixed to a plurality of the rotational support cradles 110 which areattached to cinch tubes 140, which are in turn adjustably inserted intoand secured in pilings 150 anchored in the ground and arranged in rowsat a nominal spacing of 12 to 17 feet. The distance between pilings canbe varied over a wider range if the panel mounting rails are sizedaccordingly. The rotational support beams 160 are mounted to the cinchtubes 140 by means of the rotational support cradle 110 and spliceclamps 190 that clamp the rotational support beams to the rotationalsupport cradle 110. The rotational support cradle 110 is pivotallyhinged on the cinch tubes 140 via the pivot bracket 130 and pivot pin120, which are aligned with the solar panel axis of rotation.

This simple adjustment device can be used to adjust cylindrical solarcollectors that already have single axis tracking for the east westmovement but are currently in a fixed southern exposure angle.

This manual angular adjustment of a ganged array could be used to shifta group of assembly or inspection tables to facilitate these processes.And angular adjustments can be accomplished at any time by a singleoperator. Therefore, changes in the angle of inclination throughout theseasons can be made within a few hours for even the largest of arrays.

The above disclosure is sufficient to enable one of ordinary skill inthe art to practice the invention, and provides the best mode ofpracticing the invention presently contemplated by the inventor. Whilethere is provided herein a full and complete disclosure of the preferredembodiments of this invention, it is not desired to limit the inventionto the exact construction, dimensional relationships, and operationshown and described. Various modifications, alternative constructions,changes and equivalents will readily occur to those skilled in the artand may be employed, as suitable, without departing from the true spiritand scope of the invention. Such changes might involve alternativematerials, components, structural arrangements, sizes, shapes, forms,functions, operational features or the like.

Therefore, the above description and illustrations should not beconstrued as limiting the scope of the invention, which shall be definedby claims when and as filed.

1. An adjustable tilt solar panel support system, comprising: at leastone support post; a rotational support cradle pivotally connected toeach of said at least one support post; adjustment apparatus operativelycoupling each of said rotational support cradles to each of said supportposts at an axis of rotation; and beam holders for securing at least onesolar panel support beams atop each of said rotational support cradles.2. The adjustable tilt solar panel support system of claim 1, whereinsaid adjustment apparatus includes a pivot bracket attached to saidsupport post in a generally upright orientation and having a pivot pinhole for accommodating a pivot pin and at least one adjustment opening.3. The adjustable tilt solar panel support system of claim 1, whereinsaid rotational support cradle includes a pivot pin hole in alignmentwith said pivot pin hole of said pivot bracket, such that said supportcradle is pivotally attached to said pivot bracket, said support cradlefurther including at least one adjustment opening which aligns with saidat least one adjustment opening of said pivot bracket.
 4. The adjustabletilt solar panel support system of claim 1, further including anadjustment pin selectively inserted into one of said at least oneadjustment opening of said pivot bracket, wherein the removal of saidadjustment pin permits said rotational support cradle to pivot on saidpivot bracket about said pivot pin.
 5. The adjustable tilt solar panelsupport system of claim 1, wherein said adjustment apparatus comprisesan adjustment pin selectively inserted into one of said at least oneadjustment opening of said pivot bracket, wherein the removal of saidadjustment pin permits said rotational support cradle to pivot on saidpivot bracket about said pivot pin.
 6. The adjustable tilt solar panelsupport system of claim 1, including a plurality of said support postsdisposed in a row, wherein a plurality of solar panels mounted atop saidsupport beams can be collectively rotated in unison about theirrespective axes of rotation.
 7. The apparatus of claim 1, wherein saidsupport cradle comprises substantially parallel elongate side barsconnected by a plurality of cross bars.
 8. The apparatus of claim 7,wherein each of said side bars includes an expanded medial portion inwhich said adjustment holes are disposed.
 9. The apparatus of claim 7,wherein said side bars of said rotational support cradle include aplurality of aligned angle adjustment holes in a generally arcuatearray, such that as the rotational support cradle is rotated relative tothe pivot bracket, the angle adjustment holes can be aligned in variousangular positions for insertion of an alignment pin.
 10. The apparatusof claim 7, wherein said side bars of said rotational support cradleseach include an arcuate slot disposed in relation to said adjacent sidebar, such that as said rotational support cradle is rotated relative tothe pivot bracket, a fastener can be placed through the arcuate slots tosecure said rotational support cradle in a selected angular orientation.11. The apparatus of claim 1, wherein said support post comprises acinch tube for vertically adjustable insertion into a ground anchoredsupport piling.
 12. The apparatus of claim 1, wherein said beam holderscomprise clamps disposed atop said rotational support cradle.
 13. Theapparatus of claim 1, further including an angular adjustment toolcomprising: an arm having two angled fingers that fit over medialshoulders on one of said side bars of said rotational support cradle,and two angled base elements that fit under the same of said side barsof said rotational support cradle so as to grip said side bar; anadjustment bracket installed on said support post and having a threadedfemale element proximate said support post for receiving a threaded maleend of a rotatable adjustment rod, said adjustment rod having anadjustment knob disposed at its other end and being pivotally connectedto a lower end of said arm at a pivotal connection point such that itcan be rotated freely at said pivotal connection point as said knob isturned during adjustment operations.
 14. The adjustable tilt solar panelsupport system of claim 13, including a plurality of said support postsdisposed in a row, wherein a plurality of solar panels mounted atop saidsupport beams can be collectively rotated in unison about theirrespective axes of rotation.
 15. The apparatus of claim 13, wherein saidthreaded female element is swivelable.
 16. The adjustable tilt solarpanel support system of claim 1, including a plurality of said supportposts disposed in a row, wherein a plurality of solar panels mountedatop said support beams can be collectively rotated in unison abouttheir respective axes of rotation.